Segmented pultrusion die and method of making same

Abstract

There is disclosed a method of making a segmented pultrusion die, said method comprising the steps of: selecting a first block having a first length sized to permit end cutting along an axis of said first block; end cutting said first block along said axis thereof, to form a first die segment having a first cavity extending therethrough, said first cavity having a first cross-sectional profile, selecting a second block having a second length; processing said second block to form a second die segment having a second cavity extending therethrough, said second cavity having a second cross-sectional profile which matches said first cross-sectional profile; aligning said first and said second die segments together to match said first cross-sectional profile together with said second cross sectional profile to form a continuous die having a constant cross-sectional profile; and securing said aligned first and second die segments together to permit said segmented pultrusion die to be used in place of a single die. Also disclosed is a segmented pultrusion die comprising a first die segment, a second die segment, said first die segment being adjoined to said second die segment, and a means for securing the first die segment to the second die segment.

1 . A method of making a segmented pultrusion die, said method comprising the steps of: 
 selecting a first block having a first length sized to permit end cutting along an axis of said first block;    end cutting said first block along said axis thereof, to form a first die segment having a first cavity extending therethrough, said first cavity having a first cross-sectional profile,    selecting a second block having a second length;    processing said second block to form a second die segment having a second cavity extending therethrough, said second cavity having a second cross-sectional profile which matches said first cross-sectional profile;    aligning said first and said second die segments together to match said first cross-sectional profile together with said second cross sectional profile to form a continuous die having a constant cross-sectional profile; and    securing said aligned first and second die segments together to permit said segmented pultrusion die to be used in place of a single die.    
   
   
       2 . A method of making a segmented pultrusion die as claimed in  claim 1  wherein said second length is sized to permit end cutting said second block along an axis thereof; and said step of processing said second block includes the step of end cutting said second block along said axis thereof to form said second die segment having said second cavity extending therethrough.  
   
   
       3 . A method of making a segmented pultrusion die as claimed in  claim 1  wherein said first length and/or said second length is less than or equal to 18 inches.  
   
   
       4 . A method of making a segmented pultrusion die according to  claim 1 , wherein said first length and said second length are the same.  
   
   
       5 . A method of making a segmented pultrusion die according to  claim 1 , wherein said first length and said second length are different.  
   
   
       6 . A method of making a segmented pultrusion die according to  claim 1 , wherein at least one of said first and said second block is a metal block.  
   
   
       7 . A method of making a segmented pultrusion die according to  claim 6 , wherein said metal block is steel.  
   
   
       8 . A method of making a segmented pultrusion die according to  claim 1 , further comprising the steps of: 
 selecting a further block having a length sized to permit end cutting along an axis of said further block;    end cutting said further block along said axis thereof, to form a further die segment having a cavity extending therethrough, said cavity having a cross-sectional profile;    aligning said further die segment and said segmented pultrusion die to match said constant cross-sectional profile of said segmented pultrusion die; and    securing said aligned further die segment and said segmented pultrusion die together.    
   
   
       9 . A method of making a segmented pultrusion die as claimed in  claim 1 , wherein said step of aligning said first and second die segments together includes the step of providing a first aperture on an end of said first die segment, and a second aperture on an end of said second die segment in matching relation to said first aperture, and positioning a pin between said first and second die segments to cooperate with said first and said second apertures.  
   
   
       10 . A method of making a segmented pultrusion die as claimed in  claim 1 , wherein said step of aligning said first and second die segments together includes the step of providing at least one tongue member on said first die segment or said second die segment, and at least one cooperating groove on the other of said first die segment or said second die segment.  
   
   
       11 . A method of making a segmented pultrusion die as claimed in  claim 1 , wherein said step of securing said first and said second die segments together includes the step of welding said first die segment to said second die segment.  
   
   
       12 . A method of making a segmented pultrusion die as claimed in  claim 1 , wherein said step of securing said first and said second die segments together includes the step of bonding said first die segment to said second die segment using an adhesive.  
   
   
       13 . A method of making a segmented pultrusion die as claimed in  claim 1 , wherein said step of securing said first and said second die segments together includes the step of securing at least one attachment member proximate to an end of either of said first die segment or said second die segment.  
   
   
       14 . A method of making a segmented pultrusion die as claimed in  claim 13 , wherein said step of securing said at least one attachment member proximate to an end of either of said first die segment or said second die segment includes the step of using a threaded fastener or welding.  
   
   
       15 . A method of making a segmented pultrusion die as claimed in  claim 14 , wherein said step of securing said first and said second die segments together further includes the step of securing said at least one attachment member proximate to an end of the other of said first or said second die segments with a threaded fastener or by welding.  
   
   
       16 . A method of making a segmented pultrusion die as claimed in  claim 1 , wherein said step of securing said first and said second die segments together comprises the steps of: 
 providing a fastener having a head and a threaded shank;    securing at least one attachment member proximate to an end of either of said first or second die segments, said attachment member defining an aperture large enough to allow said shank, but not said head, of said threaded fastener to pass therethrough;    forming a threaded bore sized and shaped to cooperate with said threaded shank of said fastener on the other of said first or second die segments from said attachment member, in matching relation to said aperture, wherein when said first and said second die segments are aligned, said threaded bore is aligned with said aperture; and    securing said aligned first and second die segments together by securing said fastener through said aperture in said threaded bore.    
   
   
       17 . A method of making a segmented pultrusion die as claimed in  claim 1 , wherein said step of securing said first and said second die segments together comprises the steps of: 
 providing a first member on said first die segment, said first member being positioned proximate to an end of said first die segment that is to be adjoined to said second die segment;    providing a second member on said second die segment, said second member being positioned proximate to an end of said second segment that is to be adjoined to said first segment;    axially forcing said first and second members towards one another.    
   
   
       18 . A method of making a segmented pultrusion die as claimed in  claim 17 , wherein said first member includes a first opening, and said second member includes a second opening, and wherein said step of axially forcing said first and said second members towards one another employs a threaded fastener positioned through said first and second opening.  
   
   
       19 . A method of making a segmented pultrusion die as claimed in  claim 17 , wherein said step of axially forcing said first and said second members towards one another employs a clamp.  
   
   
       20 . A segmented pultrusion die made by the method of  claim 1 .  
   
   
       21 . A segmented pultrusion die comprising: 
 a first die segment having a first cavity extending therethrough formed by end cutting a first block along an axis thereof; said first block having a first length sized to permit end cutting along said axis of said first block; said first cavity having a first cross-sectional profile;    a second die segment having a second cavity extending therethrough formed from a second block, wherein said second block has a second length, and wherein said second cavity has a second cross-sectional profile which is matches said first cross-sectional profile;    said first die segment being adjoined to said second die segment with said first and second cavities aligned to form a continuous die having a continuous cavity with a constant cross-sectional profile;    a means for securing said first die segment to said second die segment.    
   
   
       22 . A segmented pultrusion die as claimed in  claim 21 , wherein said second die segment having said second cavity extending therethrough is formed by end cutting said second block along an axis thereof; said second length being sized to permit end cutting along said axis of said second block.  
   
   
       23 . A segmented pultrusion die as claimed in  claim 21 , wherein said first length and/or said second length is less than or equal to 18 inches.  
   
   
       24 . A segmented pultrusion die according to  claim 21 , wherein said first length and said second length are the same.  
   
   
       25 . A segmented pultrusion die according to  claim 21 , wherein said first length and said second length are different.  
   
   
       26 . A segmented pultrusion die according to  claim 21 , wherein at least one of said first and said second blocks is a metal block.  
   
   
       27 . A segmented pultrusion die according to  claim 26 , wherein said metal block is steel.  
   
   
       28 . A segmented pultrusion die according to  claim 21 , further comprising: 
 a further die segment having a cavity extending therethrough formed by end cutting a further block along an axis thereof; said further block having a length sized to permit end cutting along said axis of said further block; said first cavity having a cross-sectional profile; said further die segment and said segmented pultrusion die being secured together with said cavity and said continuous cavity aligned together to match said cross-sectional profile with said constant cross-sectional profile.    
   
   
       29 . A segmented pultrusion die as claimed in  claim 21 , wherein said means for securing said first die segment and said second die segment together includes a means for aligning said first and second cavities.  
   
   
       30 . A segmented pultrusion die as claimed in  claim 29 , wherein said means for aligning said first die segment and said second die segment together includes a first aperture on an end of said first die segment, and a second aperture on an end of said second die segment in matching relation to said first aperture, and a pin positioned between said first and second die segments to cooperate with said first and said second apertures.  
   
   
       31 . A segmented pultrusion die as claimed in  claim 29 , wherein said means for aligning said first die segment and said second die segment together includes at least one tongue member on said first die segment or said second die segment, and at least one cooperating groove on the other of said first die segment or said second die segment.  
   
   
       32 . A segmented pultrusion die as claimed in  claim 21 , wherein a means for securing said first die segment and said second die segment together comprises a weld joint between said first die segment and said second die segment.  
   
   
       33 . A segmented pultrusion die as claimed in  claim 21 , wherein said means for securing said first die segment and said second die segment together comprises at least one attachment member.  
   
   
       34 . A segmented pultrusion die as claimed in  claim 33 , wherein said attachment member includes an alignment portion to align said first and second die segments before said first and second die segments are secured together.  
   
   
       35 . A segmented pultrusion die as claimed in  claim 33 , wherein said at least one attachment member is secured to both said first die segment and said second segment with threaded fasteners or by welding.  
   
   
       36 . A segmented pultrusion die as claimed in  claim 21 , wherein said means for securing said segments together comprises: 
 a first attachment member located proximate to an end of one of said first segment or second segments,    a second attachment member located proximate to an end of said other segment, and    a means to axially force said first and second members towards one another.    
   
   
       37 . A segmented pultrusion die as claimed in  claim 36 , wherein said means to axially force said first and second members towards one another comprises a threaded fastener.  
   
   
       38 . A segmented pultrusion die as claimed in  claim 21 , wherein said means for securing said first die segment to said second die segment comprises at least one threaded fastener on one of said first or said second die segments, said threaded fastener being aligned with a corresponding threaded bore on the other of said first or said second die segment, said threaded bore being sized and shaped to cooperate with said threaded fastener.